DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of Invention:
A SYSTEM AND METHOD FOR ECO-PARBOILING OF PADDY

APPLICANT:
AGRI PROCESS INNOVATIONS TECHNOLOGIES LLP

An Indian entity having address as:
No.164 & 165, KIADB, Obedenahalli Industrial Area, 3rd Phase, Doddaballapur, Bangalore – 560125 Karnataka. India

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from Indian provisional patent Application No. 202341036058 Filed On 24th May 2023.
TECHNICAL FIELD
The present disclosure relates to the field of an agriculture processing. More particularly, the present disclosure relates to a system and a method for processing of paddy, which provides environment friendly (eco-friendly) parboiling of paddy with minimal water usage.
BACKGROUND
This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
Rice is a widely cultivated and consumed staple food crop across the globe. The process of parboiling paddy, which involves soaking, steaming, and drying, is a traditional practice in many countries. However, the traditional/conventional parboiling techniques without modern technology face the challenges for the rice milling industry and have negative environmental impacts. The production costs associated with parboiling, including water usage, wastewater treatment, and electrical power, are expected to rise due to factors such as climate change and increased agricultural intensity.
More specifically, the soaking process during parboiling utilizes about 1.3 times the paddy volume which is non-eco-friendly. The soaked water can’t be reused / drained without treatment.
The conventional techniques used for processing paddy, specifically in the context of parboiling, typically rely on manual labor and lack the efficiency and sophistication of existing automated technology. In the traditional process, paddy is soaked, steamed, and dried to achieve the desired parboiled state. However, this process poses several disadvantages such as human error, limited reach to customers, delay in order fulfillment, dependency on human labor, etc. Further, the conventional techniques fail to maximize the productivity and throughput.
Therefore, there is a long-standing need for an improved system and a method for environment friendly paddy parboiling which can alleviate at least the drawbacks and/or challenges associated with the conventional techniques used for processing paddy.
SUMMARY
This summary is provided to introduce concepts related to a system and a method for eco-parboiling of paddy, and the concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
In an implementation, a system for processing of paddy is disclosed. The system may comprise a plurality of processing stations. The plurality of processing stations comprises a molecular hydration surge bin (MHSB), and a hydro-stabilization system. The molecular hydration surge bin (MHSB) may be configured to receive a paddy from a preceding station and hold the paddy for a predetermined period of time. The hydro-stabilization system may be configured to receive the paddy from the MHSB. The hydro-stabilization system comprises a molecular hydration system, a dynamic mixing chamber, an intra-granular hydro stabilization tank, and a moisture stabilization tank. The molecular hydration station may comprise one or more cylindrical chambers. Each cylindrical chamber may comprise a molecular hydration branched sparger system and a nozzle arrangement on an inner surface of the one or more cylindrical chambers at predefined positions to provide mist to the paddy thereby obtaining hydrated paddy. The dynamic mixing chamber may comprise one or more mixing chambers. Each mixing chamber may comprise a paddy distribution sparger system at the center which is configured to uniformly mix the hydrated paddy by tumbling and rotating each grain of the hydrated paddy at a predefined angle thereby obtaining uniformly mixed hydrated paddy. The dynamic mixing chamber may transfer the uniformly mixed hydrated paddy to the intra-granular hydro stabilization tank. The intra-granular hydro stabilization tank may comprise an intra-granular hydro stabilization sparger system. The intra-granular hydro stabilization sparger system may comprise a plurality of tetrad pipes configured to distribute saturated steam under pressure in the intra-granular hydro stabilization tank to achieve an efficient parboiling and homogenous gelatinization of starch of the uniformly mixed hydrated paddy thereby obtaining parboiled paddy.
In another implementation, a method for processing of paddy is disclosed. The method may comprise a step for receiving an input paddy by a molecular hydration surge bin (MHSB) through a feeding elevator from a preceding station. The method may further comprise a step for feeding the input paddy from the MHSB into one or more cylindrical chambers of a molecular hydration station. The method may further comprise a step for hydrating the input paddy received at the one or more cylindrical chambers, through a molecular hydration branched sparger system and a nozzle arrangement on the inner surface of the one or more cylindrical chambers of the molecular hydration system thereby obtaining hydrated paddy, wherein the molecular hydration system may be configured to introduce the mist during the process of hydration of the paddy inside the molecular hydration system. The method may comprise a step for transferring the hydrated paddy from the molecular hydration system to a dynamic mixing chamber. The method may comprise a step for mixing and tumbling the hydrated paddy uniformly in the dynamic mixing chamber using a branched paddy distribution sparger system, thereby obtaining uniformly mixed paddy. The method may further comprise a step for transferring the uniformly mixed paddy from the dynamic mixing chamber to an intra-granular hydro stabilization tank. The method may further comprise a step for distributing saturated steam under pressure to the uniformly mixed paddy in the intra granular hydro stabilization tank through a plurality of tetrad pipes of to achieve an efficient parboiling and homogenous gelatinization of starch of the uniformly mixed paddy using an intra-granular hydro stabilization sparger system, thereby obtaining parboiled paddy.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer to features and components.
Figure 1 illustrates an assembly of a system for eco-parboiling paddy (100), in accordance with an embodiment of the present disclosure.
Figures 2A-2B illustrate a lateral view and a transverse view of a molecular hydration system (103), respectively, in accordance with an embodiment of the present disclosure.
Figure 3A illustrates a lateral view of a molecular hydration branched sparger system, in accordance with an embodiment of the present disclosure.
Figure 3B illustrates a transverse view of a branched molecular hydration sparger system, in accordance with an embodiment of the present disclosure.
Figure 3C illustrates a tetrad pipe nozzle (301) arrangement of the molecular hydration system (103), in accordance with an embodiment of the present disclosure.
Figure 3D illustrates nozzles arrangement on the periphery of the molecular hydration system, in accordance with an embodiment of the present disclosure.
Figure 4 illustrates a dynamic mixing chamber (104), in accordance with an embodiment of the present disclosure.
Figure 5A illustrates a lateral view of a branched paddy distribution sparger system, in accordance with an embodiment of the present disclosure.
Figure 5B illustrates a transverse view of a branched paddy distribution sparger system, in accordance with an embodiment of the present disclosure.
Figure 6 illustrates an intra granular hydro stabilization tank (105), in accordance with an embodiment of the present disclosure.
Figure 7A illustrates a lateral view of an intra granular hydro stabilization sparger system, in accordance with an embodiment of the present disclosure.
Figure 7B illustrates a transverse view of an intra granular hydro stabilization sparger system, in accordance with an embodiment of the present disclosure.
Figure 7C illustrates a series of horizontal slits of an intra granular hydro stabilization sparger system, in accordance with an embodiment of the present disclosure.
Figure 8 illustrates a method for processing of paddy, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
The terms “comprise”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system or method. In other words, one or more elements in a system or apparatus preceded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
The terminology “molecular hydration surge bin (102)”, “MHSB”, “surge bin (102) has the same meaning and are used alternatively throughout the specification.
The terminology “molecular hydration branched sparger system (204)”, “sparger system” have the same meaning and are used alternatively throughout the specification.
The terminology “Resistance Temperature Detector sensor”, “RTD sensor” have the same meaning and are used alternatively throughout the specification.
The terminology “Programmable Logic Controller”, “PLC” have the same meaning and are used alternatively throughout the specification.
Referring now to figure 1, an assembly of a system for processing of paddy (100) is illustrated, in accordance with an embodiment of the present subject matter. The assembly of the system for processing of paddy (100) may comprise a plurality of processing stations. The plurality of processing stations comprises a molecular hydration surge bin (MHSB) (102), and a hydro-stabilization system. The molecular hydration surge bin (MHSB) (102) may be configured to receive a paddy from a preceding station and hold the paddy for a predetermined period of time. In one embodiment, the preceding station may be selected from a group consisting of, but not limited to, a gel cook station, a super aging station and a paddy storage. Further, the paddy received from the preceding station is one of: a gel cooked paddy, a super aged paddy, and a stored paddy. In one embodiment, the stored paddy may be a harvested paddy.
In one exemplary embodiment, the super aging cooker may be dedicated for super ageing of the paddy. Further, the super aged paddy (after super ageing) may be then fed to the hydro-stabilization system.
The hydro-stabilization system may be configured to receive the paddy from the MHSB (102). The hydro-stabilization system may comprise a molecular hydration system (103), a dynamic mixing chamber (104), an intra-granular hydro stabilization tank (105), and a moisture stabilization tank.
Further, the vertical channels (101) depicted in figure 1 may be equipped with an inlet end to receive the paddy from the preceding station or a container, and a discharge mechanism at the outlet end to efficiently release the processed paddy.
The system may further comprise a feeding elevator, the molecular hydration surge bin (MHSB) (102), an inlet hopper, a plurality of high and low-level sensor, super aging station, a hydro-stabilization system, a rotary discharge gates, a belt conveyer, a distribution box, a RTD sensor, a stainless-steel inlet pipe, a set of gel cook station, a drier and a Programmable Logic Controller (PLC), which are not shown in figure 1.
The molecular hydration surge bin (102) may be configured to receive the paddy through the feeding elevator via the inlet hopper. The paddy may be transferred from the molecular hydration surge bin (102) into the cylindrical chambers of the molecular hydration system (103) of the hydro-stabilization system. The plurality of high and low-level sensors of the molecular hydration surge bin (102) may be configured to regulate the paddy level in the molecular hydration surge bin (102), ensuring a continuous micro hydration process.
In one embodiment, the molecular hydration surge bin (102) may be made of stainless steel, and it acts as a storage container that temporarily holds the paddy. Further, the molecular hydration surge bin (102) may be configured to feed the paddy to cylindrical chambers of the molecular hydration system (103) in a continuous mode and may be then regulated with the help of the plurality of high and low-level sensors mounted on the molecular hydration surge bin (102).
The signals from high and low-level sensors may be linked with the Programmable logic controller (PLC) for maintaining the paddy for continuous micro hydration process. The molecular hydration surge bin (102) may be fabricated using stainless steel for handling steamed/wet paddy.
Now referring to figs. 2A-2B, a lateral view and transverse view of the molecular hydration system (103), is illustrated. The molecular hydration system (103) may further comprise a plurality of cylindrical chamber (201, 202, 203), a molecular hydration branched sparger system (204), an inlet end (205), an outlet end (206) and a plurality of tetrad pipes (301) as shown in figure 3C. The inlet end (205) of the molecular hydration system (103) may be connected with the outlet end of the molecular hydration surge bin (102) and the outlet end (206) of the molecular hydration system (103) may be connected to the inlet end of the dynamic mixing chamber (104). The plurality of cylindrical chambers (201, 202, 203) of the molecular hydration system (103) may comprise a nozzle arrangement on an inner surface of the one or more cylindrical chambers (201, 202, 203). Further, the molecular hydration branched sparger system (204) of the molecular hydration system (103) may be placed at the center of the plurality of cylindrical chambers (201, 202, 203). The molecular hydration branched sparger system (204) may comprise the plurality of tetrad pipes (301). Further, the plurality of tetrad pipes (301) may comprise a plurality of nozzles arranged equidistant from each other and at a predefined angle. As can be seen from figure 3C, each tetrad pipe of the plurality of tetrad pipes (301) is having an offset angle with respect to one or more adjacent tetrad pipes (301). The primary molecular hydration inlet pipe may be connected to the plurality of the cylindrical chambers (201, 202, 203).
In one embodiment, the molecular hydration system (103) may comprise the plurality of the cylindrical chambers (201, 202, 203) with truncated cones with shell attachment on the top and bottom to form a cylindrical assembly. In one embodiment, a periodic pressure spray assembly may be arranged across the cylindrical assembly at pre-defined location with the help of nozzle arrangement on the inner surface of the cylindrical chambers to facilitate or maximize the spray efficiency, thereby getting the uniform micro hydration for each and every paddy entering the molecular hydration system (103).
In addition to the nozzle arrangement on the inner surface of the cylindrical chambers, the molecular hydration system (103) may include the molecular hydration branched sparger system (204) placed at the center of the plurality of cylindrical chamber (201, 202, 203). In one embodiment, the molecular hydration branched sparger system (204) may comprise an arrangement of pressure spray units at a precise angle in order to provide uniform micro hydration to the paddy within the molecular hydration system (103).
In one exemplary embodiment, the molecular hydration system (103) may include the molecular hydration branched sparger system (204) and along with a nozzle arrangement on the inner surface of the cylindrical chambers at predefined positions to evenly micro hydrate the paddy across the chamber thereby obtaining hydrated paddy. Further, the molecular hydration branched sparger system may comprise a main axis and the plurality of tetrad pipes (301). The plurality of nozzles arranged on the main axis, the branched sparger system placed at the center of the plurality of cylindrical chambers (201, 202, 203), and on the inner surface of the cylindrical chambers. The nozzle arrangement on the inner surface of the cylindrical chamber also referred as “peripheral nozzles”.
In one exemplary embodiment, the main axis comprises twelve nozzles with an inclination angle of 65 degrees.
In another exemplary embodiment, each tetrad pipe of the branched sparger system may comprise four branches. In one exemplary embodiment, each tetrad pipes of the branched sparger system may be inclined from the central axis at an angle of 105 degrees. Further, each branch may comprise two nozzles each arranged near and farther away from the main pipe with an inclination angle of 90 degree and 75 degree with respect to an axis of the tetrad pipe.
In yet another exemplary embodiment, the peripheral nozzles may be arranged on the inner surface of the cylindrical chambers. A top shell of each cylinder chamber may comprise sixteen peripheral nozzles with an inclination angle of 52 degree, a middle cylindrical part includes twenty-eight peripheral nozzles with an inclination angle of 90 degree and the lower shell may comprise four peripheral nozzles with an inclination angle of 54 degree.
In one embodiment, the molecular hydration system (103) may be configured to hydrate the received paddy through the branched molecular hydration sparger system, the tetrad pipe nozzle, and a jet spray nozzle.
The molecular hydration system (103) may constitute a dynamic micro hydro jet spray system forming a vertical channel consisting of three cylindrical chambers arranged one above the other.
In another exemplary embodiment, the dynamic micro jet spray system comprises two types. A first type jet spray system may be associated with the branched sparger system and a second type jet spray system may be aligned within the inner periphery of the molecular hydration system. The first type jet spray system may comprise a mixing chamber (not shown in the figure) which is external to the molecular hydration system. The mixing chamber may be configured for the mixing of air and a hot water in a predetermined ratio to utilize only 20-30 percent of water.
In one embodiment, the mixing chamber may be fed with the hot water and air. The mixing chamber may be configured to generate and supply mist to the molecular hydration branched sparger system (204).
However, the periphery nozzles may be configured to deliver the required water ratio of 20-30 percent directly without the utilization of the mixing tank. The sequential spraying in three sets brings about desirable changes in the hydration chemistry of the paddy.
The design and processing of the jet spray nozzle in the molecular hydration system may involve the application of the mixing chamber and nozzles. The mixing chamber may be configured to generate a high velocity between the liquid i.e. hot water and the air. The contact between air and the hot water results in the formation of fine spray which is deduced to involve around 20-30 percent of water creating fine mist within the mixing chamber. The desired hydration of paddy is achieved with deduced intensity of spray system.
The total height of molecular hydration system (103) may be about 4878 mm which may include three cylindrical chambers each measuring 1623 mm excluding the surge bin (102).
In one exemplary embodiment, the molecular hydration system (103) may consist of an integrated jet spray nozzle arrangement on the branched molecular hydration sparger system (204) along with the nozzle arrangement on the inner surface of the cylindrical chambers at predefined positions to evenly micro hydrate the paddy across the chamber. The branched molecular hydration sparger system (204) may receive mist from the mixing chamber and the nozzle arrangement on the inner surface of the cylindrical chambers may receive mist by controlling or fine tuning an intake of hot water and air via inlet pipes, therefore the molecular hydration system (103) may be referred as the integrated jet spray nozzle arrangement.
In one exemplary embodiment, the total number of jet spray nozzles lining at each cylindrical chamber may be 76.
In one exemplary embodiment, four nozzles may be placed at the bottom of each cylindrical chamber of the plurality of the cylindrical chamber (201,202,203) for introducing the pressurized air intermittently during the hydration process. The molecular hydration system (103) may include a total of 228 nozzles. A fine mist of jet spray may be accomplished by the mixing the air with hot water at a predefined rate. The spray angle created at each nozzle may be around 45-60 degrees.
Referring now to figure 3A, a lateral view of the molecular hydration branched sparger system (204) is illustrated, in accordance with an embodiment of the present subject matter.
As shown in figure 3A, the molecular hydration branched sparger system (204) may be placed at the center of the plurality of cylindrical chambers (201, 202, 203) of the molecular hydration system (103). The molecular hydration branched sparger system (204) may constitute a series of nozzles placed at a definite angle to facilitate maximum hydration of paddy in minimum time. A total of 28 nozzles may be included in the branched sparger system of each molecular hydration system (103). The angle of the nozzle and the spray angle may maximize the efficiency of hydration running throughout the cylindrical chambers. The angle of the branches of the molecular hydration branched sparger system (204) may also facilitate the tumbling of the paddy improving the hydration efficiency.
Each sparger system may consist of a two-level arrangement of horizontal pipes. Each level may be distinctly arranged in cross to the other. In an exemplary embodiment, the branched sparger pipes of the molecular hydration branched sparger system (204) may be enabled to be placed at an inclination angle of 45 degree corresponding to the succeeding tetrad unit in such a way to cover the total area across the central axis.
The primary molecular hydration inlet pipe may be connected to the cylindrical chambers of the molecular hydration system (103). In an exemplary embodiment, the connection may be enabled through a 33.4 mm outer diameter line. The distance between each nozzle on the main sparger pipe may gradually decrease towards the base. This arrangement may be deduced following a series of trials and tests meeting the requirement of maximum efficiency.
The contour shape of the molecular hydration system (103) may help in tumbling and distribution of the paddy while travelling down from the entry towards the exit of the cylindrical chamber thereby receiving the uniform micro hydration for all the paddy grains.
Now referring to figure 3B, a transverse view of a branched molecular hydration sparger system is illustrated, in accordance with an embodiment of the present subject matter. The molecular hydration branched sparger system (204) may be configured for hydration process of the paddy inside the plurality of cylindrical chambers (201, 202, 203) by introducing the water with pressure. In one embodiment, the molecular hydration branched sparger system (204) may comprise a series of horizontal nozzles arranged on the plurality of tetrad pipes (301) emerging from a central vertical sparger line. These nozzles may be designed at varying degrees located at the two sides and or on the undersurface of the plurality of tetrad pipes (301). In an exemplary embodiment, the outer measurement of the molecular hydration branched sparger system (204) and the plurality of tetrad pipes (301) may be of 33.4 mm diameter.
Referring now to Figure 3C, the nozzle arrangement on the plurality of tetrad pipe (301) of the molecular hydration system (103) is illustrated, in accordance with an embodiment of the present subject matter. In addition to the nozzles for the molecular hydration system (103), four nozzles may be arranged equidistant from each other at the bottom of the cylindrical chambers of the molecular hydration system (103). These four nozzles may be involved in an intermittent and sequential discharge of pressurized air from the base of the cylindrical chambers during the molecular hydration process in the molecular hydration system (103). This result in uniform recirculation of residual water across the plurality of cylindrical chambers (201, 202, 203) and help in imbibition of water into the paddy.
In an exemplary embodiment, the angle between the arms within the plurality tetrad pipes (301) may be set at 45 degree from each other. In one exemplary embodiment, the plurality of tetrad pipes (301) may cover a total length of 1514 mm and a tetrad sparger diameter of 414 mm, respectively. The plurality of tetrad pipes may have two alternate arrangements of nozzles. These nozzles may also be placed at a predefined position apart from the tetrad pipes (301). In an exemplary embodiment, the outer measurement of the molecular hydration branched sparger system (204) and the tetrad pipes (301) may be of 33.4 mm diameter.
Referring to Figure 3D, the nozzles arrangement (302) in the periphery or inner surface of the molecular hydration system (103) is illustrated, in accordance with an embodiment of the present subject matter. In the embodiment, the one or more cylindrical chambers (201, 202, 203) are provided with truncated cones having shell attachment on the top and at the bottom to form a cylindrical assembly. The nozzle arrangement may be provided across the cylindrical assembly at a predefined location on the inner surface of the one or more cylindrical chambers (201, 202, 203). The nozzle arrangement (302) may be configured to periodically spray mist under pressure at a precise angle in the cylindrical assembly.
The nozzle arrangement (302) is in the shape of an inverted “v” which is present across the chamber at both top and bottom ends of the cylindrical chamber. In an exemplary embodiment, the angle formed at the junction of the inverted v in the top cone is 63.86 degree while the angle at the cylindrical drum is 40 degree. This design has been derived to maximize the spraying efficiency and hydration rate.
The desired position of the nozzles in the molecular hydration system may bring about optimum spray across the paddy as it moves downwards. The inclination angle of the nozzles was deduced after a series of trails which met the requirements with maximum efficiency of the fine spray. This design facilitates three-dimensional spray treatment and equal distribution of humidified atmosphere across the cylindrical chamber for uniform quality of paddy.
Therefore, the configuration of the molecular hydration system (103) as described in figures 2A, 2B, 3A, 3B, 3C and 3D may enable the three-dimensional micro hydro treatment across the cylindrical chambers for uniform paddy quality. In an exemplary embodiment, the water requirement for the hydration of the paddy may be about 20% and the pressure parameters of the water and air may be 0.02 bars and 2 bars, respectively. In an exemplary embodiment, the output of soaked paddy from the molecular hydration system (103) may be around 11 tons per hour. However, this output may vary based on the paddy variety and the intensity of parboiling employed.
Additionally, each cylindrical chamber of the plurality of cylindrical chambers (201, 202, 203) may be equipped with a Resistance Temperature Detector (RTD) sensor and a level sensor. The Resistance Temperature Detector (RTD) sensors may be mounted on each cylindrical chamber of the plurality of the cylindrical chambers (201, 202, 203) which may ensure to attain and maintain the required moisture and temperature acquisition to the paddy within the molecular hydration system (103). Further, the Resistance Temperature Detector (RTD) sensors may help in regulating the sealed rotary discharge gate (RDG) for the paddy discharge controlled by the Programmable Logic Controller (PLC). In an exemplary embodiment, the speed of the emerging paddy may be regulated by the sealed rotary discharge gate which may vary between 6 to 10 rpm depending on process and the paddy variety.
The molecular hydration system (103) may be configured to discharge the processed paddy from the outlet end (206) of the molecular hydration system (103) to the dynamic mixing chamber (104) of the hydro-stabilization system.
Referring now to Figure 4, the dynamic mixing chamber (104) is illustrated, in accordance with an embodiment of the present subject matter. The dynamic mixing chamber (104) may comprise one or more mixing chambers (401, 402), wherein each mixing chamber comprises a paddy distribution sparger system (403) at the center which is configured to uniformly mix the hydrated paddy by tumbling and rotating each grain of the hydrated paddy at a predefined angle, thereby obtaining uniformly mixed hydrated paddy.
The dynamic mixing chamber (104) may be configured to mix the paddy uniformly by using the paddy distribution sparger system (403) within the mixing chamber. In one embodiment, the one or more mixing chamber (401, 402) may consist of at least two mixing chambers made up of stainless-steel with truncated cones with shell attachment on the top and bottom forming a cylindrical assembly. This design of the mixing chamber may facilitate the retention and uniform mixing of paddy.
Additionally, the dynamic mixing chamber (104) may include the paddy distribution sparger system (403) which may be placed at the centre of the dynamic mixing chamber. This sparger system may be mainly involved in tumbling and mixing of the paddy by creating an angle for the paddy to rotate a maximum of 360 degree for uniform and proper mixing of hydrated paddy. Further, the dynamic mixing chamber (104) may have a discharge mechanism at the outlet end to discharge the processed paddy, wherein the rotary discharge gates, the belt conveyer and a distribution box may facilitate the discharge mechanism of paddy to the intra granular hydro stabilization tank (105) as shown in figure 1.
In one exemplary embodiment, the hydrated paddy moves from the molecular hydration system to the mixing tank through the sealed rotary discharge gate (RDG) is controlled by the PLC.
The sealed rotary discharge gate (RDG) may be positioned below the molecular hydration system and the dynamic mixing chamber. The primary function of the sealed rotary discharge gate (RDG) is to limit the leakage of water during the process. Further, the sealed rotary discharge gate (RDG) discharges the paddy which is controlled by the Programmable Logic Controller (PLC).
As the name suggest, the dynamic mixing chamber (104) may comprise the sparger system without any perforations, therefore referred as “a dummy central sparger system”. The dummy central sparger system comprises a branched tetra pipe arrangement (3 steps per sparger unit) which involves the gravity-based tumbling of the paddy while it travels down from the inlet towards the outlet, thereby getting the mixing of the paddy grains within the two successive chambers for a brief period of time. This mixing facilitates the paddy for the Intra granular hydro stabilization tank.
Further, the dynamic mixing chamber (104) may be configured to discharge the hydrated and uniformly mixed paddy from the outlet end of the dynamic mixing chamber (104) to the intra granular hydro stabilization tank (105) of the hydro-stabilization system, wherein the intra granular hydro stabilization tank (105) may comprise a dynamic pressurized chamber, the RTD sensor, a safety release valve with pressure gauge, a rotary paddle type level sensor, a rubber gasket and a toggle clamp across the rim of the top cover, the stainless-steel inlet pipe, and the intra-granular hydro stabilization sparger system (603). The Intra granular hydro stabilization sparger system may be placed at the center of the intra granular hydro stabilization tank (105).
In one exemplary embodiment, the dynamic mixing chamber (104) may consist of two cylindrical mixing chambers which may cover a total height of 4122 mm and the diameter at the center may be 1204 mm. In an exemplary embodiment, the upper and lower truncated cones of the mixing chambers may be attached to the central cylinder at a curvature angle of 54 degrees. This design may facilitate the retention and uniform mixing of paddy.
Referring now to figure 5A, a lateral view of the branched paddy distribution sparger system (403) is illustrated, in accordance with an embodiment of the present subject matter. The branched paddy distribution sparger system (403) may be placed at the centre of the dynamic mixing chamber (104). This branched paddy distribution sparger system (403) may be mainly involved in tumbling of the paddy by creating an angle for the paddy to rotate a maximum of 360 degree for uniform and proper mixing of hydrated paddy. The zig zag arrangement of the branched paddy distribution sparger system (403) may facilitate equal distribution of the pressurized micro hydro mist for the paddy introduced within the mixing chamber.
Referring now to figure 5B, transverse view of the branched paddy distribution sparger system (403) is illustrated, in accordance with an embodiment of the present subject matter. The branched paddy distribution sparger system (403) may be mainly involved in tumbling of the paddy creating an angle for the paddy to rotate a maximum of 360 degree for uniform and proper mixing of hydrated paddy.
In one embodiment, the outlet (405) of the dynamic mixing chamber (104) may be connected to the input of the intra granular hydro stabilization tank (105). The plurality of mixing chamber (401, 402) of the dynamic mixing chamber (104) may comprise a discharge mechanism at the outlet end to discharge the processed paddy. Further, the branched paddy distribution sparger system (403) of the dynamic mixing chamber (104) may be placed at the centre of the one or more of mixing chambers.
Further, the hydrated and uniformly mixed paddy from the dynamic mixing chamber (104) may be discharged from the one or more mixing chambers to the intra granular hydro stabilization tank (105), wherein the discharge mechanism may be facilitated through the rotary discharge gates, the belt conveyer, and a distribution box. Here, the distribution box may be configured for sequential distribution of paddy, with equilibrium moisture, to the plurality of the intra granular hydro stabilization tank (105) through the knife edge pneumatic gate valve.
The intra-granular hydro stabilization tank (105) may be configured to process the paddy by applying the high-pressure saturated steam or saturated steam under pressure through the inlet pipe of the intra-granular hydro stabilization tank. Further, the intra granular hydro stabilization tank (105) may have a discharge mechanism at the outlet end to discharge the processed paddy through a specialized knife edge pneumatic gate valve.
Further, the intra granular hydro stabilization tank (105) may be configured to discharge the processed paddy from the outlet end of the intra granular hydro stabilization tank (105) to a moisture stabilization bin (106) (shown in figure 1) for the resting process.
Further the parboiling process of the paddy may be followed by the stabilization of the processed paddy in the vapor pressure molecular stabilization tank for a pre-determined time.
Referring now to figure 6, the intra granular hydro stabilization tank (105) is illustrated, in accordance with an embodiment of the present subject matter.
The intra granular hydro stabilization tank (105) may further comprise a dynamic pressurized chamber, the RTD sensor, the stainless-steel inlet pipe, and the intra-granular hydro stabilization sparger system (603). The input (601) of the intra granular hydro stabilization tank (105) may be connected to the outlet (405) of the dynamic mixing chamber (104) which is conveyed through various elements and the output (602) of the intra granular hydro stabilization tank (105) may be connected to the input of the moisture stabilization bin (106). The input (601) and output (602) end of the intra granular hydro stabilization tank (105) may be configured to regulate the pressure inside the tank by the involvement of the knife edge pneumatic gate valve.
The intra granular hydro stabilization tank (105) may be involved in eco-parboiling of paddy by applying the pressure. The inlet pipe of the Intra granular hydro stabilization tank (105) may be configured to apply the high pressure saturated steam, wherein the intra granular hydro stabilization tank (105) may be configured to achieve an efficient parboiling and homogenous gelatinization of starch of the paddy.
The intra granular hydro stabilization tank (105) may constitute a dynamic pressurized chamber operating in a continues or online mode. This unit may be fabricated with a cylindrical geometrical shape with a sealed top and a lower outlet with a truncated cone assembly at the base. The top assembly may consist of a shell which may be sealed and includes an inlet vent for the paddy and a safety release valve for the release of excess steam during pressure parboiling process.
The intra granular hydro stabilization tank (105) may also include the RTD sensor for monitoring the temperature and to regulate the online processing of paddy at both the top and bottom region of the tank. Furthermore, the intra granular hydro stabilization tank may include the rotary paddle type level sensor to precisely control the level of paddy within the tank. In an exemplary embodiment, the total length and width of the intra granular hydro stabilization tank (105) may be 5812 and 1890 mm respectively. For pressure parboiling, the steam may be introduced through the stainless-steel inlet pipe mounted on the upper cylindrical area. The key factor within the intra granular hydro stabilization tank (105) may be a Intra granular hydro stabilization sparger system. The Intra granular hydro stabilization sparger system may be placed at the center of the intra granular hydro stabilization tank (105).
Referring now to figure 7A, a lateral view of an intra granular hydro stabilization sparger system is illustrated, in accordance with an embodiment of the present subject matter. The intra granular hydro stabilization sparger system may be placed at the center of the intra granular hydro stabilization tank (105). The intra-granular hydro stabilization sparger system (603) may comprise a plurality of tetrad pipes (603a) configured to distribute mist in the intra-granular hydro stabilization tank (105) to achieve an efficient parboiling and homogenous gelatinization of starch of the uniformly mixed hydrated paddy thereby obtaining parboiled paddy.
Referring to Fig 7A and 7B, the length of the plurality of tetrad pipes (603a) may be increased in ascending order at each step or level.
Further, the plurality of tetrad pipes (603a) may be supported by the central stainless-steel blades (701) positioned below each tetrad pipes. The dimension of the blades varies according to the length of the tetrad pipe. These blades add strength to the intra-granular hydro stabilization sparger system (603) and the tetrad pipe to withstand the pressure during the process.
Referring to Fig 7C, the intra granular hydro stabilization sparger system may encompass a unique design with a series of horizontal slits (702) at the base of the central pipe and on the plurality of tetrad pipes emerging from a central pipe.
These slits may be introduced at varying degrees placed at the three sides covering the lower and two sides of the tank. In an exemplary embodiment, each intra granular hydro stabilization sparger system may consist of thirteen level arrangement of horizontal pipes each level distinctly arranged in cross to the other with ascending arm length. In an exemplary embodiment, the total length of the Intra granular hydro stabilization sparger system (branched sparger system) may be 4138 mm from top to the base.
In an exemplary embodiment, the tetrad pipes may cover a diameter ranging between 508 to 1508 mm inside the intra granular hydro stabilization tank (105). Further, the efficacy of the intra granular hydro stabilization tank (105) may be achieved by the integration of the instruments involved and the PLC regulated by the Applicant’s own proprietary software (PROSE software) in an online or continuous process involving fully automated controlled system, which may be essential for reducing the process time, steam efficiency and to obtain uniform pressure parboiling of paddy. The application of high-pressure saturated steam to the paddy may increase the parboiling efficiency by achieving the maximum homogenous gelatinization of starch.
Referring now to figure 7B, a transverse view of the intra granular hydro stabilization sparger system is illustrated, in accordance with an embodiment of the present subject matter. In an exemplary embodiment, the branching pipes of the Intra granular hydro stabilization sparger system may be inclined at an angle of 10 degree corresponding to the succeeding tetrad unit covering the overall area across the central axis.
The paddy after processing through the Intra granular hydro stabilization tank (105) may be left to a resting process for a brief period in the moisture stabilization bin (106). This resting time is essential for the paddy to attain required moisture stabilization and to acquire the desired paddy characters including the color which may be based on the customer preference. The resting process may ensure the attainment of uniform color across the grain resulting in zero process rejections. Once the paddy attains the desired characteristics at a pre-determined time, paddy may be discharged to the next level.
In one exemplary embodiment, the intra-granular hydro stabilization tank (105) may be operated in the continues or online mode. The intra granular hydro stabilization tank (105) may be fabricated with a cylindrical geometrical shape with a sealed top and a lower outlet with a truncated cone assembly at the base.
In another embodiment of the present disclosure, the method (800) for processing of paddy is disclosed.
At step (801), the molecular hydration surge bin (102) (MHSB) may be configured for receiving the input paddy through the feeding elevator from the preceding station.
At step (802), the input paddy from MHSB (102) may be fed into one or more cylindrical chambers (201, 202, 203) of a molecular hydration station (103).
At step (803), the input paddy received at the one or more cylindrical chambers (201, 202, 203) may be hydrated through the branched molecular hydration sparger system (204) and the nozzle arrangement (302) on the inner surface of the one or more cylindrical chambers (201, 202, 203) of the molecular hydration system (103) thereby obtaining hydrated paddy. The molecular hydration system (103) may be configured to provide mist during the process of hydration of the paddy inside the molecular hydration system (103).
At step (804), the hydrated paddy may be transferred from the molecular hydration system (103) to a dynamic mixing chamber (104).
At step (805), the hydrated paddy may be mixed and tumbling performed uniformly in the dynamic mixing chamber (104) using the branched paddy distribution sparger system (403) thereby obtaining uniformly mixed paddy.
At step (806), the uniformly mixed paddy may be transferred from the dynamic mixing chamber to the intra-granular hydro stabilization tank.
At step (807), the saturated steam under pressure may be distributed to the uniformly mixed paddy in the intra granular hydro stabilization tank (105) through the plurality of tetrad pipes of to achieve an efficient parboiling and homogenous gelatinization of starch of the uniformly mixed paddy using an intra-granular hydro stabilization sparger system (603), thereby obtaining parboiled paddy.
At step (808), the parboiled paddy may be transferred into the moisture stabilization bin (106), wherein the moisture stabilization bin (106) is configured to allow the parboiled paddy to rest and achieve the required moisture stabilization and desired characteristics, including colour uniformity of the parboiled paddy.
At step (809), the final gel cook station (107) may be configured for providing final steaming (809) to the parboiled paddy.
At step (810), the parboiled paddy may be further transferred and rested in a resting station (108).
At step (811), the parboiled paddy may be discharged in the drying station (109) for drying the parboiled paddy until the parboiled paddy reaches a safe moisture level.
Overall, the system and method of paddy processing provides an environment friendly paddy parboiling which is a strong, reliable, and efficient solution for processing paddy with improved quality, uniformity, and productivity.
The present system and method address the water utilization issue by reducing the water consumption by 80% during the soaking process. And this process involves a fine mist spray technology termed as “the molecular hydration system” to impart the required water for paddy soaking. This process brings about minimal use of water for soaking process.
The presently disclosed system and method of environment friendly paddy parboiling may have the following advantageous functionalities over the conventional art:
? Superior parboiled rice production with minimal soaking requirements
? Reduced water consumption of approximately 20%
? Efficient utilization of water, steam, and electricity resources
? Output of parboiled rice with high milling and eating quality
? Enhanced cooking properties of the final product
? Environmentally friendly approach.
The system and method for eco-parboiling of paddy may offer a more flexible, efficient, automated and cost-effective approach to paddy processing.
The system and method for eco-parboiling of paddy may provide an automated system which reduces the reliance on manual labor, minimizes human errors, increases efficiency, minimizes water requirements while ensuring the essential parboiling of paddy and improving the quality of the final product and improves the overall productivity of the rice milling industry.
Additionally, the system and method for processing of paddy may offer advantage of handling large and continuous batches of paddy efficiently, with a processing capacity of up to 8-12 tons per hour.
Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure.
The embodiments, examples, and alternatives of the preceding paragraphs or the description, including any of their various aspects or respective individual feature(s), may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.
,CLAIMS:WE CLAIM:
1. A system (100) for processing of paddy, characterized in that, the system (100) comprises, a plurality of processing stations, wherein the plurality of processing stations comprises:
a molecular hydration surge bin (MHSB) (102) configured to receive a paddy from a preceding station and hold the paddy for a predetermined period of time; and
a hydro-stabilization system configured to receive the paddy from the MHSB (102), wherein the hydro-stabilization system comprises a molecular hydration system (103), a dynamic mixing chamber (104), an intra-granular hydro stabilization tank (105), and a moisture stabilization tank (106);
wherein the molecular hydration station (103) comprises one or more cylindrical chambers (201, 202, 203), wherein each cylindrical chamber comprises a molecular hydration branched sparger system (204) and a nozzle arrangement (302) on an inner surface of the one or more cylindrical chambers (201, 202, 203) at predefined positions to provide mist to the paddy thereby obtaining hydrated paddy;
wherein the dynamic mixing chamber (104) comprises one or more mixing chambers (401, 402), wherein each mixing chamber comprises a paddy distribution sparger system (403) at the center which is configured to uniformly mix the hydrated paddy by tumbling and rotating each grain of the hydrated paddy at a predefined angle thereby obtaining uniformly mixed hydrated paddy, wherein the dynamic mixing chamber (104) transfers the uniformly mixed hydrated paddy to the intra-granular hydro stabilization tank (105); and
wherein the intra-granular hydro stabilization tank (105) comprises an intra-granular hydro stabilization sparger system (603), wherein the intra-granular hydro stabilization sparger system (603) comprises a plurality of tetrad pipes (603a) configured to distribute saturated steam under pressure in the intra-granular hydro stabilization tank (105) to achieve an efficient parboiling and homogenous gelatinization of starch of the uniformly mixed hydrated paddy thereby obtaining parboiled paddy.
2. The system (100) as claimed in claim 1, wherein the preceding station is selected from a group comprising of: a gel cook station, a super aging station and a paddy storage, wherein the paddy received from the preceding station is one of: a gel cooked paddy, a super aged paddy, and a stored paddy.
3. The system (100) as claimed in claim 1, wherein the system (100) comprises a mixing chamber fed with hot water and air, wherein the mixing chamber is configured to generate and supply mist to the molecular hydration branched sparger system (204).
4. The system (100) as claimed in claim 1, wherein the molecular hydration branched sparger system (204) comprises a main axis and a plurality of tetrad pipes (301), wherein the plurality of tetrad pipes (301) comprise a plurality of nozzles arranged in equidistant manner and at a predefined angle, wherein each tetrad pipe of the plurality of tetrad pipes (301), is having an offset angle with respect to one or more adjacent tetrad pipes (301).
5. The system (100) as claimed in claim 1, wherein the one or more cylindrical chambers (201, 202, 203) are provided with truncated cones having shell attachment on the top and at the bottom to form a cylindrical assembly, and wherein the integrated jet spray nozzle arrangement on the inner surface (302) of the one or more cylindrical chambers (302) is configured to periodically spray mist under pressure at a precise angle in the cylindrical assembly.
6. The system (100) as claimed in claim 5, wherein the nozzles in the nozzle arrangement (302), are arranged in an inverted V shape.
7. The system (100) as claimed in claim 1, wherein the one or more mixing chambers (401, 402) containing the branched paddy distribution sparger system (403) are provided with truncated cones having shell attachment on the top and at the bottom to form a cylindrical assembly.
8. The system (100) as claimed in claim 1, wherein the intra-granular hydro stabilization tank (105) is configured to process the uniformly mixed hydrated paddy by applying the saturated steam under pressure through the inlet pipe of the intra-granular hydro stabilization tank, wherein the intra granular hydro stabilization tank (105) discharges the processed paddy through a knife edge pneumatic gate valve into the moisture stabilization bin (106) for the resting process.
9. The system (100) as claimed in claim 1, wherein each tetrad pipe of the plurality of tetrad pipes (603a), comprises slits along the length of the respective tetrad pipe, wherein the slits are configured to distribute saturated steam under pressure in the intra-granular hydro stabilization tank (105).
10. The system (100) as claimed in claim 1, wherein the intra-granular hydro stabilization tank (105) operates in a continues or online mode, wherein intra granular hydro stabilization tank (105) is fabricated with a cylindrical geometrical shape with a sealed top and a lower outlet with a truncated cone assembly at the base.
11. The system (100) as claimed in claim 1, wherein the intra-granular hydro stabilization sparger system (603) is placed at the center of the intra-granular hydro stabilization tank (105), wherein the intra-granular hydro stabilization sparger system (603) comprises one or more spargers (603-a), wherein one or more spargers (603-a) comprises a series of horizontal slits at the base of the central pipe and on the tetrad pipes emerging from the central pipe, wherein the slits are introduced at varying degrees placed at the three sides covering the lower and two lateral sides of one or more spargers (603-a).
12. The system (100) as claimed in claim 1, wherein the plurality of processing stations comprise a feeding elevator (101), a final gel cook station (107), a resting station (108) and a drying station (109);
wherein the feeding elevator (101) is configured to feed the paddy to the MHSB (102);
wherein the final gel cook station (107) is installed after the moisture stabilization tank (106) and configured to provide final gel cooking to the parboiled paddy;
wherein the resting station (108) is installed after the final gel cook station (107) and configured to provide rest to the parboiled paddy;
wherein the drying station (109) is installed after the resting station (108) and configured to dry the parboiled paddy.
13. The system (100) as claimed in claim 1, wherein the system (100) comprises a plurality of sensors, wherein the plurality of sensors comprises:
a plurality of high and low-level sensors configured to regulate the paddy level in the plurality of stations;
a Resistance Temperature Detector (RTD) sensor mounted on each cylindrical chamber of the one or more cylindrical chambers (201, 202, 203) to ensure that the paddy attains and maintains the required moisture and temperature within the molecular hydration system (103), wherein the Resistance Temperature Detector (RTD) sensor is configured to regulate a rotary discharge gate (RDG) for the paddy discharge controlled by the Programmable Logic Controller (PLC);
a safety release valve with pressure gauge, wherein the safety release valve is configured to maintain safe and desired pressure levels for operating the plurality of processing stations;
wherein the plurality of sensors is communicatively connected with a programmable logic controller (PLC), wherein the PLC is configured to control the plurality of sensors as per requirement.
14. A method (800) for processing of paddy, the method comprising:
receiving (801) an input paddy at a molecular hydration surge bin (102) (MHSB) through a feeding elevator (101) from a preceding station;
feeding (802) the input paddy from MHSB (102) into one or more cylindrical chambers (201, 202, 203) of a molecular hydration station (103);
hydrating (803) the input paddy received at the one or more cylindrical chambers (201, 202, 203), through a molecular hydration branched sparger system (204) and a nozzle arrangement (302) on an inner surface of the one or more cylindrical chambers (201, 202, 203) of the molecular hydration system (103) thereby obtaining hydrated paddy, wherein the molecular hydration system (103) is configured to provide mist during the process of hydration of the paddy inside the molecular hydration system (103);
transferring (804) the hydrated paddy from the molecular hydration system (103) to a dynamic mixing chamber (104);
mixing and tumbling (805) the hydrated paddy uniformly in the dynamic mixing chamber (104) using a branched paddy distribution sparger system (403) thereby obtaining uniformly mixed paddy;
transferring (806) the uniformly mixed paddy from the dynamic mixing chamber (104) to an intra-granular hydro stabilization tank (105);
distributing (807) saturated steam under pressure to the uniformly mixed paddy in the intra granular hydro stabilization tank (105) through a plurality of tetrad pipes of the intra granular hydro stabilization tank (105) to achieve an efficient parboiling and homogenous gelatinization of starch of the uniformly mixed paddy using an intra-granular hydro stabilization sparger system (603) thereby obtaining parboiled paddy.
15. The method (800) as claimed in 14, comprising
transferring (808) the parboiled paddy into the moisture stabilization bin (106), wherein the moisture stabilization bin (106) is configured to allow the parboiled paddy to rest and achieve the required moisture stabilization and desired characteristics, including colour uniformity of the parboiled paddy;
providing final steaming (809) to the parboiled paddy via a final gel cook station (107);
transferring and resting (810) the parboiled paddy in a resting station (108);
discharging (811) the parboiled paddy in a drying station (109) for drying the parboiled paddy until the parboiled paddy reaches a safe moisture level.
Dated this 24th day of May 2024